Electrical connector



May 28, 1963 E. K. WILLIAMS 3,091,745

ELECTRICAL CONNECTOR Filed July 24, 1961 IN VE N TOR Patented May 28, 1963 3,091,745 ELECTRICAL CONNECTOR Edwin K. Williams, Indianapolis, Ind., assignor to Western Electric Company, Incorporated, a corporation of New York Filed July 24, 1961, Ser. No. 126,011 3 Claims. (Cl. 339-492) This invention relates to an electrical connector, and more particularly to a sheet metal connector for receiving, holding and electrically contacting the thin portion of a spade lug. It is an object of the invention to provide an improved connector of such character.

In the manufacture of electrical apparatus, and particularly communications equipment, a large number of electrical connections are commonly required, many of which involve the connection of a wire terminal to a connector which is adapted to hold and electrically contact the terminal. Because of the large number of connections of this type, the simplification of such connections is a matter of considerable commercial importance.

Previously known forms of connectors have various undesirable characteristics. Conventional screw terminals provide good electrical contact and firm securing of a wire end or lug but require the use of a screw driver and significant time to effect the connection, and are furthermore, relatively expensive. Various forms of quick connectors which reduce the time required for the completion of a connection generally are either costly to manufacture, fail to provide firm electrical contact, fail to grip the Wire terminal or lug securely, and/or are so fragile as to be unreliable in use.

It is another object of the invention to provide an improved electrical connector to which a spade lug may be quickly and easily connected without the use of tools.

It is a further object of the invention to provide an improved electrical connector which makes firm electrical contact with and securely grips a spade lug.

Another object of the invention is to provide an improved electrical connector having various of the characteristics referred to above while being reliable in operation, and economical to manufacture.

An electrical connector constructed in accordance with the present invention is formed of sheet metal with a flap folded back against a base portion of the sheet to form a pocket. This pocket is arranged to receive snugly the thin portion of a spade lug such that firm electrical connection is made therewith. A tab is punched from the base portion close to a side of the pocket which is adjacent the folded edge, this tab protruding from the same side of the base portion as the flap and having its free end extending generally toward the folded edge of the pocket. With a spade lug inserted in the pocket the lug may be turned such that the wire receiving portion of the lug is moved over the tab substantially in the direction in which the tab extends. Accidental removal of the lug from the connector is resisted by the tab. More particularly, the wire receiving portion of the lug may not be moved back over the tab unless the tab is first depressed. Further, the spade lug cannot be removed through the side of the pocket since it cannot pass between the tab and the folded edge of the pocket. Preferably, a tab is provided at opposite sides of the pocket such that the thin portion of the spade lug may be securely held within the pocket with the wire receiving portion of the lug extending in either of two opposite directions.

The invention, together with further objects and ad vantages thereof, will best be understood by reference to the following description taken in connection with the accompanying drawing, in which FIG. 1 is an end elevational view of an electrical connector illustrating one embodiment of the invention, and

FIG. 2 is a front elevational view of the same connector.

The connector illustrated in the drawing is formed of .008 gauge sheet Phosphor bronze. Sheet metal of other material and of other gauge or thickness may, of course, be employed as desired according to the particular application of the connector. It is highly desirable that the connector be formed of sheet metal, however, since this permits low cost production of the connector.

The connector consists primarily of a base sheet 11 provided with legs 12 and apertured feet 13 through which it may conveniently be mounted on a suitable base, not shown. The upper edge portion of the base sheet is bent in the manner shown in FIG. 1 to provide a spring detent 14. This detent serves to hold a cylindrical light bulb in place with one of its terminals in contact with the connector, the position of the bulb beiiig suggested by phantom lines in FIG. 1.

A flap 15 is folded back upon a portion of the base sheet 11 to form a pocket. The flap 15 and the cooperating portion of the base sheet may be so formed as to be in pressure contact as shown in FIG. 1, or may be spaced a short distance apart. It is necessary, however, that they normally lie sutficiently close to each other as to firmly contact opposed surfaces of the thin portion of a spade lug 16 when the latter is inserted in the pocket defined by these two parts.

In the illustrated embodiment of the invention, the connector is shown in cooperation with a form of lug which is frequently referred to as either a C-lug or a U- clip. It is to be understood, however, that the connector is cooperable with various forms of spade lug. More particularly, it is cooperable with any form of terminal having a shank for receiving a wire end and a somewhat broader and generally thinner spade portion. The spade lug 16 illustrated in the drawing is connected to a wire 17 through soldering or crimping.

Close to the righthand side of the pocket defined by the flap 15 and the associated portion of base sheet 11 is a tab 29 which is punched from the base sheet. It will be noted that the tab 20 protrudes from the same side of base sheet 11 as the fiap 15, and that its free end extends generally toward the folded edge 21 of the pocket. Preferably, a second tab 22 identical to the first tab 20 is arranged on the opposite side of the pocket.

The spade lug 16 is most readily brought into cooperation with the connector by insertion of the thin portion of the spade lug into the pocket through the top of the pocket, that is, through the side opposite the folded edge 21. The spade lug is then turned through an angle of such that the wire receiving shank portion of the lug is moved over the tab 20 while the thin portion of the lug rotates within the pocket. Movement of the shank of the lug past the tab 20 is facilitated by the fact that the tab is directed as specified above, namely, with its free end extending generally toward the folded edge 21 of the pocket. This entire operation may readily be performed without the use of tools.

Rotation of the lug in the opposite direction is resisted by engagement of the free end of the tab 20 with the shank of the lug, the tab 20 and the shank of the lug functioning generally as a ratchet. Neither can the spade lug 16 be retracted from the pocket through the side of the pocket to which the tab 20 is adjacent, namely, the righthand side of the pocket as viewed in FIG. 2, since the thin or spaded portion of the lug is too wide to pass between the tab 20 and the folded edge of the pocket. Still further the spade lug 16 cannot be removed through the lefthand side of the pocket since the shank 16 of the lug is too thick to enter the pocket. Accordingly, the spade lug cannot be removed from the connector except by first depressing the tab 20 or through the application of destructive forces.

The second tab 22 described above is desirable since it permits the spade lug 16 to be turned initially to the left such that the wire or lead 17 may extend to the left. A connector provided with tabs 28' and 2 2 at opposite sides of the pocket is thus more flexible in use. It will be appreciated, however, that only one of the tabs 20 or 22 is operative in association with a single spade lug.

If desired, a central portion of the flexible flap and/or a corresponding area of the base sheet 11 may be dimpled toward the other, as suggested in FIG. 2, such that a central hearing or post is provided about which a 'C-lug or U-clip may be rotated. This post may alternatively be in the form of a tack welded dimple or dimples, or an eyelet.

In the drawing a single spade lug and hence a single wire 17 are shown secured to the connector. The securing of a single lug and lead to the connector serves a useful function where the connector itself is secured to or contacts a chassis or a component such as the illustrated light bulb. It is also contemplated that the connector might be basically isolated and serve as a juncture for two or more leads. Thus it will be seen that this connector is of broad applicability.

It will be apparent that the connector illustrated in the drawing and described above is inherently inexpensive to manufacture. A spade lug may readily be secured to the connector in firm electrical contact therewith. Still further, the lug cannot be removed from the connector except by deliberate depression of the tab 20 or 22 such that the shank of the lug may be swung past the tab in a direction away from the folded edge of the pocket.

While a single embodiment of the invention has been disclosed, many modifications will be apparent, and it is intended that the invention be interpreted as including all modifications which fall within the true spirit and scope of the invention.

What is claimed is:

1. A sheet metal connector for receiving, holding and electrically contacting the thin portion of a spade lug, said sheet metal connector comprising a base sheet, a flap folded back into closely spaced relationship with a portion of said base sheet and forming therewith a pocket for snugly receiving the thin portion of the spade lug, said pocket having a substantially unobstructed free edge, opposite the folded edge thereof, for permitting passage of the thin portion of the spade lug into the pocket, and a tab punched from said base sheet outside the pocket and closely adjacent to a side of the pocket which is adjacent the folded edge theerof, said tab being located sufiieiently close to the pocket and to the folded edge thereof that it obstructs passage of the thin portion of the spade lug between the tab and the folded edge of the pocket, said tab protruding from the same side of said base sheet as said flap and having its free and extending generally toward the folded edge of the pocket, such that a spade lug having its thin portion moved into the pocket through the unobstructed side opposite the folded edge thereof may be turned in a direction to move the wire receiving shank portion of the lug over said tab and the lug is restrained by said tab from subsequent turning in the opposite direction, said tab also resisting extraction of the lug from the pocket through the side of the pocket to which said tab is adjacent.

2. A sheet metal connector for receiving, holding and electrically contacting the thin portion of a spade lug, said sheet metal connector comprising a base sheet, a flap folded back into a closely spaced relationship with a portion of said base sheet and forming therewith a pocket for snugly receiving the thin portion of the spade lug, said pocket having a substantially unobstructed free edge, opposite the folded edge thereof, for permitting passage of the thin portion of the spade lug into the pocket and a pair of tabs punched from said base sheet outside the pocket and closely adjacent to opposed sides of the pocket which are adjacent the folded edge thereof, said tabs being located sufiiciently close to the pocket and to the folded edge thereof that they obstruct passage of the the thin portion of the spade lug between the tabs and the folded edge of the pocket, said tabs protruding from the same side of said base sheet as said flap and having their free ends extending generally toward the folded edge of the pocket, such that a spade lug having its thin portion moved into the pocket through the unobstructed side opposite the folded edge thereof may be turned in either direction to move the wire receiving shank portion of the lug over one of said tabs and the lug is restrained by said one tab from subsequent turning in the opposite direction, said tab also resisting extraction of the lug from the pocket through the side of the pocket to which said tab is adjacent.

3. A sheet metal connector for receiving, holding and electrically contacting the thin portion of a C-lug, said sheet metal connector comprising a base sheet, a flap folded back upon a portion of said base sheet, the two facing layers of material forming a pocket for snugly receiving the thin portion of the =C-lug, one of said layers of material having a dimple extending toward and engaging the other, and a tab punched from said base sheet close to a side of the pocket which is adjacent the folded edge thereof, said tab protruding from the same side of said base sheet as said flap and having its free end extending generally toward the folded edge of the pocket, such that a =C-lug having its thin portion moved into the pocket through the side opposite the folded edge thereof may be pivoted about the dimple in a direction to move the Wire receiving shank portion of the C-lug over said tab and the C-lug is restrained by said tab from subsequent turning in the opposite direction, said tab also resisting extraction of the C-lug from the pocket through the side of the pocket to which said tab is adjacent.

References Cited in the file of this patent UNITED STATES PATENTS 1,196,617 Truesdell Aug. 29, 1916 1,689,824 Goelz Oct. 30, 1928 2,626,168 Macy Q. Jan. 20, 1953 2,663,851 Pistey Dec. 22, 1953 2,679,634 Rawley May 25, 1954 2,997,685 Anderson Aug. 22, 1961 

3. A SHEET METAL CONNECTOR FOR RECEIVING, HOLDING AND ELECTRICALLY CONTACTING THE THIN PORTION OF A C-LUG, SAID SHEET METAL CONNECTOR COMPRISING A BASE SHEET, A FLAP FOLDED BACK UPON A PORTION OF SAID BASE SHEET, THE TWO FACING LAYERS OF MATERIAL FORMING A POCKET FOR SNUGLY RECEIVING THE THIN PORTION OF THE C-LUG, ONE OF SAID LAYERS OF MATERIAL HAVING A DIMPLE EXTENDING TOWARD AND ENGAGING THE OTHER, AND A TAB PUNCHED FROM SAID BASE SHEET CLOSE TO A SIDE OF THE POCKET WHICH IS ADJACENT THE FOLDED EDGE THEREOF, SAID TAB PROTRUDING FROM THE SAME SIDE OF SAID BASE SHEET AS SAID FLAP AND HAVING ITS FREE END EXTENDING GENERALLY TOWARD THE FOLDED EDGE OF THE POCKET, SUCH THAT A C-LUG HAVING ITS THIN PORTION MOVED 